Color spraying of flocked areas



Dec. 18, 1962 J.v1scARDl COLOR SPRAYING OF FLOCKED AREAS 3 Sheets-Sheetl Filed Nov. 9, 1959 INVENTOR.

dan Vsoard/ Dec. 18, 1962 Filed Nov. 9, 1959 J. VISCARDI COLOR SPRAYINGOF FLOCKED AREAS 5 Sheets-Sheet 2 IN V EN TOR.

C/a/m V/Lfcaral' Dec. 18, 1962 J. vlscARDl 3,069,285

COLOR SPRAYING OF FLOCKED AREAS Filed NOV. 9, 1959 3 Sheets-Sheet 3United States Patent Office 3,069,285v Patented Dec. 18, 1962 3,069,285COLOR SPRAYING F FLOCKED AREAS John Viscardi, Lodi, NJ., assignor toVelourit Corporation, Hoboken, NJ., a corporation of New Jersey FiledNov. 9, 1959, Ser. No. 851,768 Claims. (Cl. 117-37) This inventionrelates to the coloring of flocked or other raised areas of fabrics and,more particularly, to a simplified and flexible method of and apparatusfor applying color only to such flocked or raised areas without applyingthe color to the main body of the fabric where the fabric has a repeatedpattern.

In the flocking of fabric, finely divided particles of fragmentarymaterial, generally in ber form and of relatively short length, aredeposited or distributed in fixed relation upon a base fabric in apre-determined pattern. Usually the fixation is accomplished bypre-printing the patterned portions of the fabric with a suitableadhesive so that, when the flock material is deposited on the fabric, itwill adhere only to the adhesive .coated portions of the fabric to bepat-terned. The deposits of the flocking material on the fabric, inadhering relation to the latter, provide a raised or embossed effect forthe fabric.

In certain instances, it is desirable that the flocked portions of thefabric have a different color from the main porti-on of the fabric.Previously, such coloring of the flocked portions has been diilicult andexpensive to effect, usually requiring the use of rollers engraved inthe same pattern as the flocked portions of the fabric so that only theflocked portions will -be color printed. This naturally requires that -adifferent engraved roller be employed for coloring each differentpattern of flocking. In addition, great care must be taken to preventstretching, skewing, or other distortion of the Ifabric during printingin an attempt to secure proper registry of the flocked areas with thecorresponding engraved portions of the printing roll or rolls.

In accordance with the present invention, advantage is taken of the factthat the flocked pattern generally is repeated at pre-determinedintervals. Proceeding upon this basis, it is possible, where the flockpattern is repeated at pre-determined intervals, to apply color to theflocked areas only in a novel, inexpensive and flexible manner, notrequiring the use of engraved printing rollers or the like.

More specifically, the flocked fabric is caused to'travel over apre-determined path and, -ab'ove `this path, there are located aplurality of reservoirs of liquid coloring material in accordance withthe number of different colors desired. These reservoirs are selectivelyand interchangeably connectible to spraying heads controlled by electricvalve mean-s and effective, when the valve means are operated, to havecompressed air supplied thereto to spray color from a selected reservoirinto the fabric directly beneath the spray head. These spray heads arearranged at a pre-determined zone along the path of travel of theflocked material and, at a distance upstream therefrom equal to thelength, or to a multiple of the length, of the repeated flocked pattern,a plurality of electric switches are arranged yin another zone. Each ofthese switches has a very sensitive feeler arranged to ride along `theIfabric as i-t is drawn or otherwise moved to a position beneath thespray heads.

A In accordance with one embodiment of the invention, when one of thesefeeler-s contact a raised or embossed flocked portion of the fabric, 'itcloses its respective switch to energize the electric valve of acorrespondingly located spray head which is at a distance -fro-rn suchfeeler equal to the length of the repeated pattern, or to a multiple ofsuch length. Consequently, a spray of a particular color is thereby'directed upon a flocked portion then passing also in the center.

directly beneath the particular spray head. The spray heads may bearranged in two or more transverse rows across the path of travel of thematerial, so that a particular spray head in any selected row may beenergized at will by an associated feeler switch longitudinally alignedwith such head -along the path of travel of the material. Thereby,different colors may be applied to different portions of the flockedpattern.

In some patterns used in flocked fabric, one or more flocked areas of`one repeat of the pattern, normally substantially centered on one lineextending longitudinally of the :fab-ric, will laterally overlap theadjacent longitudinally extending line o1' lines on which one or moreother flocked areas of such repeat are normally centered. In such case,the microswitch finger or feeler normally centered on such adjacent linefor tripping by flocked areas centered therealong will be falselytripped by such laterally overlapping flocked areas, thus resulting inincorrect sprayingof the flocked areas.

Accordingly, in a preferred embodiment of the invention, keys are workedinto the flocked design adjacent either or both borders of the fab-ric,or adjacent the center or other parts of the fabric, and these keys areso positioned that only these keys will be contacted by the fingers ofthe micro-switches and not the flocked areas of the pattern. The keysare provided at the beginning of each repeat of the fabric, 'and thespraying devices controlled lby the thus-tripped micro-switches are soarranged that when a key is contacted, all the flocked areas of apreceding repeat of the fabric are sprayed simultaneously. Thus, theseveral spraying devices are initially arranged to correspond in numberand location, with all of the flocked areas of a single repeat of thepattern. Thus, when any key trips a micro-switch at the beginning of apattern repeat, all of the spraying devices then oriented over theflocked areas of a preceding repeat are -activated at once, so that all.the flocked areas in a given section of the fabric are sprayed at once.

To provide for any possi-ble misalignment, twisting, or warping of thefabric in its passage over the rolls land under the same sprayingdevices, two or more normally laterally aligned keys may be provided atthe beginning of each pattern repeat, as at both edges of the fabric andIn the case of keys so provided at both edges of the fabric, each keywould control spraying of the flocked areas of substantially one-halfthe width of the fabric and, in the case of keys located at both edgesand also at the center, each key would control spraying of the flockedareas of substantially onethird the width of the fabric.

A further situation arises in the case of certain fabrics in which theflocked areas are concentrated near the edges of the fabric, with thecenter being unllocked, and in cases where the flocking is concentratedalong the center of the fabric with the edges being unflocked In thefirst of these cases, the keys are provided only at the edges of thefabric and, in the second of these cases, the keys are provided only atthe center area of the fabric.

The keys may take any desired form, such as laterally extended flockedareas, or extensions of patterns, such `as flowers and leaves, so las toappear to be actually part of the pattern but nevertheless projectinglaterally beyond adjacent flocked areas so as to serve as projectionsinto the path of the fe'elers of the micro-switches.

For an understanding of the principles of the invention, reference ismade to the following description of a typical embodiment thereof asillustrated in the accompanying drawings. In the drawings:

FIG. l is a top plan view of an apparatus embodying the invention;

FIG. 2 is a side elevation view of the apparatus;

aoeaass FIG. 3 is a somewhat schematic partial side elevation viewillustrating the underlying principle of operation of the invention; and

FIGS 4 through 8 are plan views of flocked fabric having keysincorporated in the flocking in selected manners at the beginning ofeach repeat of the fabric for the purpose of triggering the `sprayingdevices to color spray all `the flocked areas of a preceding repeat ofthe pattern.

Referring to the drawings, the apparatus is mounted on a frame generallyindicated at 1t) and including elevated and parallel side members 11supported on columns 12, the frame having extensions 13 at the end ofeach side and supported upon shorter columns 14. Uprights 16 at one endof each side rail 11 support a cross bar 17, shown as an angle, on whichare adjustably mounted a plurality of switches 15, such asmicro-switches, adapted for adjustment along cross member 17.

Beneath cross bar 17, each rail 11 has a bearing 18 rotatably supportingthe shaft 21 of a roller 20. At its opposite end, each rail 11 hasbearings rotatably supporting the shaft 24 of a roller 25. Shafts 21 and24 have secured thereto Vsprockets 22 which are interconnected by anendless chain 23. An idler roller 26 mounted on a bracket 27 pivoted toone `rail 11 serves to maintain chain 23 taut. A second sprocket 23 onshaft 25 is connected by a chain Z9 to a sprocket 31 on the output shaft32 of a gear motor 30. It will thus be noted that rollers 2t) and 25 arerotated in -synchronism with each other, the importance of which will bepointed out more fully hereinafter.

The extension side rails 13 support outwardly opening bearings 33 whichreceive a shaft 34 on which the material 35 is wound. Thus, a fresh rollof material, wound on a shaft 34, may be readily mounted in the brackets33. The material wound on shaft 34 is led over the rollers and 25 so asto extend substantially horizontally therebetween, and a support surfacemay be provided beneath the material between the rollers, if desired.

Just in advance of roller 25, upstanding arms 36 on side rails 11 havepivoted thereto substantially horizontal arms 37 carrying, at theirouter free ends, bearings 38 rotatably receiving the shaft 41 of aroller 40. Roller 40 engages the material 35 and maintains it firmlyagainst roller for drawing of the material 35 from its supply wound onshaft 34. Due to the synchronously driven rollers 20 and 25, and theroller 40, material 35 is fed without stretching underneath switches 15and the spray heads.

Material is formed with a regular pattern of flocked or embossedportions which project from the surface of the material. In theparticular example shown, the `flocking 45 is arranged in alternate rowsof four and five flocked areas respectively. Of course, any other repeated pattern can be sprayed with the apparatus of the invention.

An elevated platform 42 supported on stilts 43 secured to side rails 11is arranged substantially above the material 35 and intermediate therolls 20 and 25. This platform supports tanks or reservoirs a, 50b, and50c, containing the color solutions to be sprayed onto the flocked areas45. All three reservoirs may contain the same color, or the color ineach of the reservoirs may differ from that in the other reservoirs inaccordance with the particular color spraying operation to be performed.

L-shaped brackets 44 comprising feet 46 and uprights 47 are mounted oneach rail 11 by means of bolts 48 extending through slots 49 in feet 46.Thereby, the brackets may be adjusted over a substantial rangelongitudinally of the rails 11. The upper ends of each laterallyopposite pair of brackets 44 are interconnected by tubular cross members51, and these cross members 51 have slidably and rotatably mountedthereon brackets 52 supl 4 porting the spray devices 55. The brackets 52are adjustable both longitudinally of the tubular cross members 51 andangularly with respect thereto so that the spray delivered by nozzle y53of each spray `device can be properly directed accurately upon a flockedarea 45. Brackets 52 are maintained in longitudinally and angu-l larlyadjusted position by means of set screws 54 threaded therein andengageable with tubular cross members 51.

Each of the spray devices 55 is provided with an electric or solenoidoperated control valve, such valve being schematically indicated by thewinding 56 of FIG. 3. Any one of the spray devices 55 may be connectedto any one of the reservoirs 50 by means -of a flexible conduit 57 sothat any particular spray device 55 may have any one of the threeavailable colors supplied thereto. As schematically illustrated, solelyby way of examplavthe left-hand row of spray devices 50 is connected toreservoir 50c, the intermediate row to reservoir Stlb, and theright-hand or leading row to reservoir 50a.

The brackets 44 are adjusted longitudinally of rails 11 so that thespacing of the brackets is equal to the distance between successive rowsof flocking 45. The spray devices 55 are adjusted along support 51 sothat each spray is longitudinally aligned with flocked areas in aparticular row of the pattern. For example, the leading row of spraydevices 55 includes four of the spray devices each aligned with one ofthe areas 45 in a row of four of the pattern, and the intermediate rowof the spray devices includes ve of these devices each aligned with oneof the area 45 in a row of five areas of the pattern. If the patternwere repeated after each third row, the trailing row of spray devices 55would be aligned longitudinally with the flocked areas of the third rowof each pattern. Also, the leading row of spray devices is adjusted soas to have a distance from switches 15 equal to the distance between twosuccessive rows of four flocking areas.

The spray devices 55 are supplied with compressed air from a main 58 byindividual connections 59 which may be flexible to provide for thenecessary adjustment of the spray devices 55. Also, each spray device iselectrically connected to the associated switches 15 by wires containedin conduits 61 connected to the several spray devices.

Referring to FIG. 3, each switch 15 includes a feeler 151 connected `toa contact arm 152 which is normally disengaged from a contact 153.Switch 15 is connected in series between a source of electric potential,connected to terminals 60, and the winding 56 of a control valve of aspray device 55. With the parts adjusted as described, when feeler 151is engaged by a raised or flocked area 45, arm 152 engages contact 153to close a circuit energizing the winding 56. This opens the valve ofthe associated sprayer 55 so that a spray of coloring material isdirected upon the flocked area 45 of the pattern preceding the one thenbeing engaged by the feeler 151 of the switches 15. As soon as feeler151 rides off a flocked area, the circuit is broken so that the controlvalve is closed.

Referring to FIG. l, it will be noted that a row of four flocked areasis passing beneath the switches 15. This correspondingly activates thespray devices '55 in the leading row thereof to spray the row of fourflocked areas then passing beneath these spray devices. When a row offive flocked areas engages the switches 15, the intermediate row ofspray devices is energized to spray the row of five flocked areas thenaligned beneath the nozzles of the intermediate row of spray devices.Thus, and where the pattern is a repeated pattern, as a trailing patternpasses beneath the feelers 151 of switches 15, a preceding pattern isautomatically and precisely sprayed with the desired color or colors.

The unsprayed flocked patterns are indicated in FIG. l by circles whichhave dots therein, whereas the sprayed flocked areas are indicated bycircles having the dots plus shading.z With the described arrangement,lspraying of any desired color upon the flocked areas of a repeatedpattern 'is effected automatically, simply, Vand economically andwithout the use of engraved rollers or the like. Itis merely necessaryto adjust the spray devices 55 later-` ally of their support rods 51,and to adjust the brackets 44 longitudinally'of the rails 11tocorrespond with the modulus of the pattern.l Also, any spray device 55can be connected to any reservoir 50 so that the color selection may bechanged from row to row or even between flocked' areas 45 ingany givenrow.

As stated previously, there are many cases wherein, due either to theirregularity of the repeated pattern or due to the fact that certainflocked areas will laterally overlap, to a substantial extent, otherflocked areas, false indications may be given by the feelers of themicroswitches. To avoid this possibility, and at the same time to obtaina more accurate and faster application .of color to the flocked areas ofthe pattern, the preferred embodiments of the fabric shown in FIGS. 4through 8 is used. In these preferred embodiments of the invention, keysare provided, preferably as part of the flocking pattern, at thebeginning of each repeat to trigger one, two, or three` micro-switcheSto simultaneously spray all the flocked areas of a preceding repeat ofthe pattern.

Referring frsttQFIG. U4,7thev fabric 35A is illustrated as havingthereon flocked areas 45A arranged in repeated patterns. The oppositelongitudinal edges of the fabric, which may be scalloped, have flockingextending therealong, as indicated at 65, and inwardly of these edges anedge pattern, likewise flocked, may be provided in the nature of floralornamentation, as indicated at 66. In this particular embodiment of theinvention, keys 70A are provided at the'start of each repeat of thepattern, these keys being flocked areas projecting toward the center ofthe fabric from one of the flowers of the pattern 66. The keys may beprovided at only one edge of fabric 35A, but preferably are provided atboth edges thereof as indicated. This takes care of any possible skewingor biasing of the fabric in its passage over the rolls 20 and 25 of FIG.2. Also, and if desired, an additional key 70A', shown in dotted outlinein FIG. 4,'

may be provided at the center of the fabric in lateral alignment withthe two keys 70A at the side edges thereof.

With this arrangement, the switches 15 are so arranged that the feelers151 of these switches are aligned only with the keys 70A and 70A. Thus,if a key is provided at only one edge of the fabric, only one switch 15and its associated feeler 151 are used. On the other hand, if the keysare provided at both edges of the fabric, two switches 15 are used, andif an additional key 70A is provided at the center of the fabric, threeswitches 15 are used. If only one switch is used, this switch is wiredto control all the spray devices 55 arranged in a number and in apattern such that all of the flocked areas 45A in a single repeat of thepattern will be aligned with the spray devices when a subsequent repeathas its keys 70A passing beneath the feeler 151 of -a switch 1'5. In theevent two keys are used, one at each edge of the fabric, each switchcontrols the spraying devices 55 arranged over one-half of the width ofthe fabric. If a third key 70A' is used at the center of the fabric,each one of the three switches controls the spraying devices forsubstantially one-third the width of the fabric. This assures proper andaccurate spraying of the flocked areas 45A of the pattern irrespecti-veof any possible skewing or misalignment of the fabric in passing beneaththe switches and the spraying heads.

FIG. 5 shows an alternative arrangement in which central flocked areas45B on a fabric 35B are provided with extensions forming keys 70B at thestart of each repeat of the flocked pattern. In this case, only onesubstantially centrally located switch and feeler 1'51 is provided, withthe feeler positioned laterally so as to intercept the keys 70B. Thissingle switch simultaneously triggers allof the spray devicescorresponding in number and locationto the number of flocked areas 45B,and their location, in a single repeat of the pattern.

. In certain patterns, the flocked areas are concentrated adjacent theside edges of the fabric and the center is left unflocked. Thus, and asshown in FIG. 6, fabric 35C is provided with flocked areas 45C adjacenteach side edge of'the fabric.A In this particular instance, the flockedpattern 66B adjacent each edge of the farbic is provided Iwithextensions forming keys 70C at the start of each repeat of the pattern.Two switches are used in this instance, each controlling spray .devices55 conjointly arranged in number and location so as to spray a completerepeat of the pattern at each activation FIG. 7 illustrates the oppositecase in which the flocked areas 45D are concentrated at the center ofthe fabric, and the areas adjacent the edges of the fabric are -leftunflocked except possibly for an edge flocking. In this instance, a pairof keys 70D are arranged to project laterally from flocked areas 45D on-the center line of the fabric and at `the beginning of each repeat ofthe pattern. Either one or two switches may be used and, if two switchesare'used, each switch controls the spray devices 55 for one-half thewidth of the flocked areas.

Referring to FIG. 8, a preferred way of providing the keys 70E is byforming these keys as relatively inconspicuous parts of the flockedpattern. In this instance, the flocked pattern is indicated as leaf orpetal arrangements 45E, with one leaf of each pattern 45E, at the startof the repeat of a pattern, being made longer than the others andprojecting toward the center of the fabric. These extensions 70E projectbeyond the lateral extent of the leaf pattern 45E at the beginning of arepeat of the fabric and thus serve to trigger two switches 15 each f ofwhich will spray one-half the Width of the flocked area of the patternin each repeat.

While a specific embodiment of the invention has been shown anddescribed in detail to illustrate the application of the inventionprinciples, it will be understood that the inventionv may be embodiedotherwise Without departing from such principles.

What is claimed is:

1. A method of coloring raised integral areas of a fabric arranged in apre-determined pattern repeated longitudinally of the fabric, saidmethod comprising the steps of moving the fabric longitudinally along apath; directly contacting the fabric at a first pre-determined pointalong such path to detect a raised integral fabric area of a repeat ofthe pattern passing such first point; and responsive to detection of araised fabric area of one repeat of the pattern at such first point,spraying at least one raised area in a preceding repeat of the patternat a second point along such path which is spaced longitudinally fromthe first point by an integral multiple of the length of the repeatedpattern at least equal to one length thereof.

2. A method as claimed in claim l in which said raised fabric areas arecorrespondingly located in each repeat and are aligned longitudinally ofsuch path.

3. A method as claimed in claim l in which the integral raised fabricareas include plural raised fabric areas spaced transversely of thefabric in each repeat thereof; and such correspondingly located raisedfabric areas are aligned longitudinally of such path.

v4. Apparatus for coloring raised integral areas of a a fabric arrangedin a pre-determined pattern repeated longitudinally of the fabric, saidapparatus comprising,

t in combination, means for moving the fabric longitudinally along apath; detecting means arranged at a predetermined point along such pathand operable by direct sensing contact with such raised integral areasof the fabric; a color spraying means arranged at a secondpre-determined point along such path spaced longitudinally from thefirst point by an integral multipleof the length of lthe repeatedpattern at least equal to one length thereof; control means for therespective color spraying means operatively connected to said detectingmeans in such manner that upon detection of a raised fabric area at onerepeat of the pattern at such rst point, at least one color sprayingmeans is activated to spray color on a raised area in a preceding repeatof the pattern at such second point.

5. Apparatus as claimed in claim 4 in which said control means compriseelectrically operated Valves for the spraying means; and said detectingmeans comprises normally open switches having sensitive feelers eacheffective to close the associated switch when the feeler is engaged witha raised integral area of the fabric to operate at least one valveconnected to such associated switch to activate the spray meansassociated with the valve.

6. Apparatus as claimed in claim 4 including a plurality of spraydevices arranged in a row transversely of such path at such secondpoint; plural reservoirs for spraying color material; and meansselectively operable to interconnect any one of said spraying devices toany one of said reservoirs.

7. Apparatus as claimed in claim 4 in which there are a row of sprayingdevices extending transversely of the path of the fabric at such secondpoint; and means for adjusting said row longitudinally of the path oftravel in accordance with the length of the repeated pattern 8 wherebyto adapt the apparatus for patterns of varying length.

8. Apparatus as claimed in claim 7 in which there are plural rows ofspraying devices each spaced longitudinally from each other by thelength of the repeated pattern.

9. Apparatus as claimed in claim 4 in which said means for moving thefabric along a path comprises a pair of longitudinally spaced driverollers; means interconnecting said rollers for synchronous rotation;and a roller engaging the fabric passing over the downstream roller tomaintain the fabric rmly engaged with the downstream roller.

10. Apparatus as claimed in claim 9 including plural reservoirs forsprayable coloring material; feed lines selectively connecting any oneof said spraying means to any one of said reservoirs; a source ofcompressed air; and electric valve means operable to connect said sourceof compressed air to a spraying nozzle associated with the controlledspraying means, responsive to operation of a detecting means.

References Cited in the tile of this patent UNITED STATES PATENTS2,368,706 Fountain Feb. 6, 1945 2,804,764 Runton Sept. 3, 1957 2,828,714Sandberg Apr. 1, 1958 2,881,516 Hull et al. Apr. 14, 1959

1. A METHOD OF COLORING RAISED INTEGRAL AREAS OF A FABRIC ARRANGED IN APRE-DETERMINED PATTERN REPEATED LONGITUDINALLY OF THE FABRIC, SAIDMETHOD COMPRISING THE STEPS OF MOVING THE FABRIC LONGITUDINALLY ALONG APATH; DIRECTLY CONTACTING THE FABRIC AT A FIRST PRE-DETERMINED POINTALONG SUCH PATH TO DETECT A RAISED INTEGRAL FABRIC AREA OF A REPEAT OFTHE PATTERN PASSING SUCH FIRST POINT; AND RESPONSIVE TO DETECTION OF ARAISED FABRIC AREA OF ONE REPEAT AT THE PATTERN AT SUCH FIRST POINT,SPRAYING AT LEAST ONE RAISED AREA IN A PRECEDING REPEAT OF THE PATTERNAT A SECOND POINT ALONG SUCH PATH WHICH IS SPACED LONGITUDINALLY FROMTHE FIRST POINT BY AN INTEGRAL MULTIPLE OF THE LENGTH OF THE REPEATEDPATTERN AT LEAST EQUAL TO ONE LENGTH THEREOF.